Architectural Covering and Method

ABSTRACT

The present application is directed to an architectural cover for securing to a support surface comprising: a frame defining a perimeter; a panel overlying a portion of the frame to form an exterior side of the cover and an interior side of the cover; the frame further comprising (a) a main body configured to attach to the panel via a fastening means, and (b) a lip defined by a first surface configured to receive a securing means, and a second surface configured to abut the support surface; the lip further comprising an outer edge defining a perimeter of the cover and an inner edge defining an inner perimeter of the frame, the perimeter of the inner edge configured to abut the support surface when the architectural cover is secured to the support surface.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

FIELD OF THE APPLICATION

The application relates generally to architectural covers to be applied to surfaces such as building walls and the like.

BACKGROUND

Architectural panels are used as cladding elements in architecture and building construction (1) to improve the aesthetics of both exterior and interior surfaces of buildings and other structures, (2) to reduce costs related to construction, (3) to lighten the weight of construction materials, (4) to improve the durability of construction, and (5) to reduce long term maintenance cost and for weather protection.

Known attachment options for securing architectural panels to a surface requires that each panel necessarily contacts at least one adjacent panel or contacts a sub-frame in order to secure, align and/or seal the panels to a surface. Thus, the attachment of a single panel to a surface is dependent on its relationship with an adjacent panel or sub-frame. For example, architectural panels may be secured to a surface by first securing a dedicated sub-frame to the surface followed by fastening individual architectural panels to the sub-frame. Another known technique involves securing individual panels directly to a surface in a sequential overlapping and/or interlocking manner.

A typical sub-frame includes a grid like structure having parallel rows and columns of equidistant elongated members pre-fastened to the surface. Thus, the distance between adjacent elongated members determines the size of panels to be attached thereto. In addition, the orientation of the sub-frame necessarily determines the directional alignment and orientation of the panels on a surface. In addition, sub-frames often have multiple parts that must be assembled, aligned and leveled, which can be both time and labor intensive. Likewise, the failure of individual panels often results from the failure of the sub-frame itself. The grid like configuration of a sub-frame also means that damage to one particular panel may cause damage to adjacent panels. For example, water leakage along the interior side of a particular panel may spread to the interior side of adjacent panels.

In the prior art, when attached in a sequential overlapping or interlocking manner, the perimeter of each successive panel overlaps or interlocks a portion of the frame of the previous panel in a sequential and directional manner, similar to applying shingles along a rooftop. In addition, as each successive row or column of panels is applied to the surface, a portion of the panel of each successive row or column necessarily overlaps a portion of the panel making up the preceding row or column. Like shingles, the overlapping panel configuration is intended, in part, to protect the target surface against water penetration, to maximize thermal efficiency, to conceal the surface from view, and to ensure proper alignment of the panels on the surface, i.e., in rows or columns. Unfortunately, the sequential application of panels means that in order to remove and/or replace a particular panel, all successive panels must be first removed to gain access to that particular panel. Thereafter, panels must be reapplied to the surface in a sequential manner to re-cover the surface, which is time consuming and labor intensive.

Hence from the foregoing, it will be appreciated that there is a need for a panel design that enables individual panels to be independently secured to a surface in a random manner to form a continuous barrier across a surface without affecting other panels that are secured to the same surface.

SUMMARY

The present application provides an architectural cover for securing to a support surface comprising: a frame defining a perimeter; a panel overlying a portion of the frame to form an exterior side of the cover and an interior side of the cover; the frame further comprising (a) a main body configured to attach to the panel via a fastening means, and (b) a lip defined by a first surface configured to receive a securing means, and a second surface configured to abut the support surface; the lip further comprising an outer edge defining a perimeter of the cover and an inner edge defining an inner perimeter of the frame, the perimeter of the inner edge configured to abut the support surface when the architectural cover is secured to the support surface.

The present application also provides a system for forming a continuous barrier on a support surface comprising: a plurality of architectural covers, the architectural covers being secured adjacent one another on the support surface forming joints there between; wherein each architectural cover forms an independent relationship with the support surface when secured to the support surface.

The present application also provides a system for forming a continuous barrier on a support surface comprising: two or more architectural covers, each cover having a frame and a panel, wherein the frame comprises three or more sides defining a perimeter, the frame being securable to the support surface; the panel overlying the frame to form an exterior side of the cover and an interior side of the cover; one or more decorative joint members; wherein the two or more covers are secured adjacent one another on the support surface forming joints there between; wherein the two or more covers form an independent relationship with the support surface when secured to the support surface; and wherein the decorative joint members are inserted at the joints between the frames of adjacent covers to conceal the joints from view.

The present application also provides a method for forming a continuous barrier on a support surface using a plurality of architectural covers, the method comprising: providing a plurality of architectural covers, each architectural cover comprising a frame defining a perimeter, and a panel overlying the frame to form an exterior side of the cover and an interior side of the cover; the frame further including a main body configured to attach to the panel via a fastening means, and a lip defined by a first surface configured to receive a securing means, and a second surface configured to abut the support surface; the lip further comprising an outer edge defining a perimeter of the cover and an inner edge defining an inner perimeter of the frame, the perimeter of the inner edge configured to abut the support surface when the architectural cover is secured to the support surface; randomly securing successive architectural covers directly to the support surface wherein the outer edges of each architectural cover share common borders with the outer edges of adjacent architectural covers.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 illustrates the random placement of four sided architectural covers onto a support surface.

FIG. 2 illustrates a perspective view of an architectural cover including the exterior side of the cover.

FIG. 3 illustrates a perspective view of an architectural cover including the interior side of the cover.

FIG. 4 illustrates a cross-sectional side view of adjacent architectural covers including abutting frames.

FIG. 5A illustrates a perspective view of adjacent architectural covers including a cross section of two adjacent covers.

FIG. 5B illustrates a cross-sectional perspective view of adjacent architectural covers including attachment of the panels to the frames and attachment of the frames to a support surface.

FIG. 6 illustrates a cross-sectional side view of an architectural cover attached at the base of a support surface.

FIG. 7 illustrates a panel configuration including a top cap on a support surface.

FIG. 8 illustrates a cross-sectional view of an architectural cover attached to the outside corner of a support surface.

FIG. 9 illustrates a cross-sectional view of the attachment of architectural covers at an inside corner of a support surface.

FIG. 10 illustrates a cross-sectional view of an architectural cover at a wall jamb.

FIG. 11 illustrates an embodiment of three sided architectural covers forming a continuous barrier on a surface.

FIG. 12 illustrates an embodiment of non-uniform shaped architectural covers of various sizes forming a continuous barrier on a surface.

FIG. 13 illustrates an embodiment of various architectural covers forming a continuous barrier on a non-rectangular support surface.

DESCRIPTION

It has been found that one or more architectural covers, each comprising a frame defining a perimeter of three or more sides and a panel overlying a portion of the frame, can be secured to a support surface as cladding to form a continuous barrier across the support surface wherein the architectural covers are secured to the support surface independent of a sub-frame and in a manner other than by sequentially contacting architectural covers in an overlapping or interlocking manner. It has also been found that architectural covers comprising a different number of sides and various sizes can be used to form a continuous barrier across a support surface. It has further been found that the frame of the architectural cover can be configured to increase the load bearing characteristics of the architectural cover. Heretofore, such a desirable achievement has not been suitably accomplished. Accordingly, the novel cover and method of this application measure up to the dignity of patentability and therefore represent a patentable concept.

Before describing the invention in detail, it is to be understood that the present architectural cover and method are not limited to particular embodiments. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting. The phrases “independent relationship,” “independently secure,” and variations thereof refer to the ability to releasably secure and/or seal an architectural cover to a support surface without necessarily contacting an adjacent architectural cover and/or a sub-frame. The term “joint” refers to space between adjacent panels, more particularly, the space between the return portion of the panels. The phrase “continuous barrier” refers to one or more covers completely covering a target surface. The phrase “self align” and variations thereof refers to the ability to align an architectural cover on a support surface at a desired orientation without necessarily contacting an adjacent architectural cover.

In one aspect, the present application provides a means for individual architectural covers to be removed from a support surface and replaced without disturbing adjacent architectural covers secured to the support surface.

In another aspect, the present application provides a means for providing a more permanent seal across a support surface.

In another aspect, the present application provides a method for forming a continuous barrier across a support surface by providing one or more architectural covers less expensive to install than known techniques.

In another aspect, the present application provides a method for forming a continuous barrier across a support surface including providing architectural covers that may be installed more quickly than known techniques.

In another aspect, the present application eliminates the necessity of a dedicated framing scheme or common intermittent attachment between architectural covers.

In still another aspect, the present application provides an architectural cover comprising a frame having a load bearing surface abutting a support surface when secured to the support surface.

In still another aspect, the present application provides an architectural cover that is light in weight.

In another aspect, the present application provides an architectural cover configuration whereby a plurality of architectural covers can be secured to a support surface using like securing means without regard to the size and shape of the architectural covers.

In yet another aspect, the present application provides an architectural cover resistant to hurricane type forces when secured to a support surface as described herein.

In another aspect, the present application provides an architectural cover that can be used as part of either a dry seal system or a wet seal system.

In another aspect, the present application provides one or more architectural covers forming a barrier across a support surface whereby the covers are secured to the support surface in a non-aligned and/or non-leveled manner.

In another aspect, the present application provides a system of architectural covers that may be secured to a support surface in a non-sequential and/or non-directional manner.

In another aspect, the present application provides a system of architectural covers for forming a continuous barrier across a support surface wherein the covers may comprise different sizes, different shapes and various numbers of sides.

In another aspect, the present application provides a system of architectural covers for forming a continuous barrier on a support surface wherein the outer edges of adjacent covers are parallel while the remaining edges of the covers are neither parallel nor perpendicular to one another.

In another aspect, the present application provides a method for forming a continuous barrier across a rectangular support surface using a plurality of architectural covers having three or more sides, whereby adjacent covers have centers that are different distances from the top and bottom edges of the support surface.

In another aspect, the present application provides a method of sealing a support surface by providing a plurality of independent architectural covers each securably sealed to the support surface in a manner effective for each of the architectural covers to collectively seal the support surface to form a continuous sealed barrier across the support surface.

In another aspect, the present application provides a system of architectural covers whereby any load placed on a particular cover when secured to a support surface does not affect any other cover secured to the same support surface.

The various characteristics described above, as well as other features, will now be described with reference to the accompanying drawings, wherein like reference numerals are used for like features throughout the several views. It is to be fully recognized that the different teachings of the embodiments disclosed herein may be employed separately or in any suitable combination to produce desired results.

Brief Description of the Architectural Cover

The architectural cover described herein suitably comprises a configuration effective for one or more architectural covers to be secured to a support surface independent of any other architectural cover and in any random order effective for forming a continuous barrier across a target support surface. In an alternative embodiment, the architectural cover described herein may be independently secured to a target support surface in a manner effective to form a seal between the architectural cover and the support surface.

With reference to FIG. 1, a simplified support surface 100 is shown including a plurality of architectural covers 10 randomly and independently secured to the support surface 100. As FIG. 1 exemplifies, it is herein contemplated that individual architectural covers 10 (herein referred to as “cover”) may be secured to a support surface 100 to form a continuous barrier on the support surface 100 in any random order and without regard to the orientation of any other cover to be secured to the support surface 100.

For example, in one embodiment a first cover 10 may be secured near an edge of a support surface 100 whereby the alignment of the first cover 10 in relation to the support surface 100 is effective to further align a second cover 10 secured to the support surface 100 adjacent the first cover 10. Likewise, all successive covers 10 to be secured to the support surface 100 may be aligned on the support surface 100 based on the alignment of a preceding adjacent cover 10. In another embodiment, a plurality of covers 10 may be randomly placed on a support surface 100 in any order and arrangement until the covers 10 form a barrier across the support surface 100. In still another embodiment, a support surface 100 can be pre-marked indicating the exact location upon which each cover 10 is to be secured to the support surface 100 to form a barrier across the support surface 100.

FIG. 2 is an illustration of an exterior side of a simplified cover 10. As shown, the cover 10 comprises a frame 12 defining a perimeter of the cover 10, and a panel 14 operationally configured to overlie a portion of the frame 12. In this particular embodiment, the frame 12 includes four substantially equidistant sides defining a perimeter wherein the panel 14 is folded over a portion of the frame 12 to form an exterior side of the cover 10 and an interior side of the cover 10. Suitably, the cover 10 described herein can be fabricated using route and return methodology known to persons of ordinary skill in the art, although other methods may be incorporated.

Suitably, the portion of the panel 14 folded over the frame 12 is releasably attached to the frame 12 by one or more fastening means 16, which allows for replacement of the panel 14 portion if necessary. Suitable fastening means 16 include, but are not necessarily limited to conventional screws, rivets, bolt type fasteners, and combinations thereof. Suitable screws include, but are not necessarily limited to stainless steel screws of T3 or T5 grade material. In addition, a sealant may be applied to the cover 10 to form a seal between the panel 14 and the frame 12. Suitable sealants include but are not necessarily limited to silicone, structural silicone, polyurethane, rubber, elastomer, and combinations thereof.

Referring now to FIG. 3, an interior side of a simplified four sided cover 10 is illustrated, including the interior side of both the frame 12 and panel 14. Depending on the desired shape of the cover 10, a suitable frame 12 may be formed from three or more longitudinal frame members each comprising a surface configuration including at least a main body 12 a portion for attaching to the panel 14, and a lip 12 b portion for attachment to a support surface 100.

In particular, the lip 12 b is suitably defined by a first surface 13 a (as illustrated in FIG. 2) and a second surface 13 b (as illustrated in FIG. 3). The lip 12 b also comprises an outer edge 18 a defining an outer perimeter of both the frame 12 and the cover 10, and an inner edge 18 b defining an inner perimeter of the frame 12.

In one embodiment, the lip 12 b may comprise one or more apertures (not shown) each operationally configured to receive a securing means 20 on the first surface 13 a for independently securing a cover 10 directly to a support surface 100. In another embodiment, the first surface 13 a of the lip 12 b may comprise a scored region 30 (see FIG. 2) operationally configured to guide a user as to proper placement of the securing means 20 on the first surface 13 a. In particular, the scored region 30 provides a user with a starting location along the first surface 13 a upon which one or more securing means 20 may be directed through the lip 12 b. Suitably, the scored region 30 comprises a groove or series of grooves along the first surface 13 a set apart from the main body 12 a a distance effective for the securing means 20 to be directed through the lip 12 b without contacting the main body 12 a of the frame 12. Thus, the lip 12 b suitably extends perpendicularly from the main body 12 a a distance effective for receiving a securing means 20 having a width up to about the width of the first surface 13 a.

The longitudinal frame members may include extruded material manufactured in various lengths, whereby a user may cut the extruded frame material into three or more sections of desired lengths and edge mitered to any angle to form a desired size and shape of cover 10. An L-type bracket (not shown) may also be used at the junction between frame members to hold the frame members together at the mitered edges. Suitably, the L-type bracket is set on the interior side of the cover 10 whereby one or more fastening means 16 penetrate the panel 14, frame 12 and L-type bracket to form a cover 10.

Suitably, the one or more securing means 20 are operationally configured to independently secure the cover 10 to a support surface 100 in a manner effective for up to about the entire second surface 13 b to abut the support surface 100. In a particularly advantageous embodiment, the inner edge 18 b of the lip 12 b abuts the support surface 100 when the cover 10 is independently secured to the support surface 100. In another particularly advantageous embodiment, the outer edge 18 a and inner edge 18 b of the lip 12 b abut the support surface 100 when the cover 10 is independently secured to the support surface 100.

The one or more securing means 20 may include, but are not necessarily limited to mounting gear such as conventional screws, nails, anchor studs, and combinations thereof. Suitable screw materials include, but are not necessarily limited to ferrous metals, non-ferrous metals, plastics and combinations thereof. In one embodiment, the screw may include a sheet metal screw such as a stainless steel screw of T3 or T5 grade material. In addition, the screws may comprise a hex shaped head to facilitate the placement of the screws within a support surface 100. The screw head may further comprise an Allen, Phillips or straight slot arrangement for directing the screws. Typical commercially available screws include a helical shape thread in a downward spiraling direction effective to penetrate a support surface 100 upon a clockwise rotation. Subsequently, when removing a cover from a support surface 100, the screws can be removed from the support surface 100 by reverse rotation, i.e., counter clockwise.

The panel 14 portion of the cover 10 is suitably constructed from one or more materials to form (1) an exterior surface of the cover 10 comprising any combination of desired aesthetic characteristics such as color, texture and surface design, and (2) an interior surface operationally configured to attach to the frame 12. Suitably, the panel 14 is constructed from one or more materials capable of being shaped, cut, and/or bent as necessary to form a particular cover 10. Likewise, the panels 14 may be flat, curved, roll formed, perforated, or hot welded. Suitably, the panel 14 comprises a sheet material made from one or more metals, composite materials, plastics, and combinations thereof. Suitable metals include, but are not necessarily limited to ferrous metals and non-ferrous metals. Although not necessarily limited to particular metals, suitable ferrous metals include for example, irons including alloys of iron, i.e., titanium and steels including stainless steel. Suitable non-ferrous metals include for example, aluminum, tin, copper, and brass. Suitable composite materials include, but are not necessarily limited to particle board, plywood, concrete, stucco, fiberboard, and sheetrock.

In one suitable embodiment, the panel 14 comprises a metal composite material including a thermoplastic core layer sandwiched between layers of metal. In a particularly advantageous embodiment, the panel 14 is an aluminum composite material including two layers of aluminum separated by a polyethylene core layer.

Depending on the application, the panel 14 material may be prefinished, for example, by coil coating or electrostatic paint. In addition, other additives may be incorporated into the panel 14 core as desired. Suitable additives include, but are not necessarily limited to basalt and synthetic fibers such as KEVLAR®. Although the cover 10 may be built to scale, a suitable panel 14 for architectural applications comprises a thickness from about 2.0 mm (about 0.08 inches) to about 7.0 mm (about 0.24 inches). In a particularly advantageous embodiment, a panel 14 comprises a thickness of about 4.0 mm (about 0.16 inches) including two layers of aluminum separated by a polyethylene material, wherein each layer of aluminum comprises a thickness of about 0.50 mm (about 0.020 inches). In addition, an exemplary panel 14 may comprise a weight of about 0.8 lb/ft² or more, although panels 14 comprising lighter weights are also contemplated.

Although it is herein contemplated that the cover 10 may comprise various configurations, including non-planar configurations, a suitable cover 10, when secured to a support surface 100, comprises a panel 14 having (1) a first outer surface 15 a defining a plane substantially parallel to the plane defining the support surface 100, and (2) a second surface 15 b defining a plane substantially perpendicular to the plane defining the support surface 100. The second surface 15 b of the panel 14 is also referred to herein as the “return portion” of the panel 14.

The frame 12 is suitably constructed from three or more rigid or semi-rigid longitudinal frame members of equal or unequal lengths that are operationally configured to maintain the cover 10 in a secured position on a support surface 100. As previously stated, the frame 12 is suitably constructed from one or more extruded materials capable of being further shaped, cut, and/or bent to form a particular shaped cover 10—the frame 12 members having a greater load capacity once formed into a cover 10. Suitable materials include, but are not necessarily limited to ferrous and non-ferrous metals, high density plastics, and ultra-high molecular weight polyethylene. Suitably metals include for example steel, aluminum, titanium, and tin. In a particularly advantageous embodiment, the frame 12 comprises extruded 6063 aluminum that is heat treated to a T5 condition.

Details focused on the relationship between adjacent covers 10 when secured to a support surface is illustrated in FIG. 4. As shown, each cover 10 comprises like frames 12, including a main body 12 a and lip 12 b whereby the main body 12 a comprises a length effective to form a cavity on the interior side of the cover 10 within the inner perimeter of the frame 12 (see FIG. 3). Although the cover 10 can be built to scale, in common architectural applications, a suitable frame 12 comprises a main body 12 a having a length of about 1.8 cm (about 0.75 inches) or more. As stated above, a suitable panel 14 comprises a thickness from 2.0 mm to about 7.0 mm. Thus, when independently secured to a support surface 100, a suitable cover 10 extends out from the support surface 100 about 2.54 cm (about 1.00 inches) or more.

The main body 12 a suitably comprises a first mating surface lying substantially perpendicular to the plane of the support surface 100 for attachment of the return portion of the panel 14 to the main body 12 a. Likewise, the main body 12 a may comprise a distal edge terminating directionally substantially perpendicular to the plane of the support surface 100. In the alternative, the main body 12 a may comprise a distal edge terminating directionally substantially parallel to the plane of the support surface 100—as shown in FIG. 4. As shown, the main body 12 a may comprise a bend up to about 90° for forming a landing surface 12 c for contacting a portion of the interior of a panel 14. As FIGS. 5A and 5B demonstrate, the panel 14 may not necessarily contact the landing surface 12 c. For example, the interior side of a panel 14 will only contact the landing surface 12 c when the depth of the panel returns are less than the length of the main body 12 a of the frame 12. Thus, when deep sided panels are used, the interior side of the panel 14 is raised above the landing surface 12 c. As stated previously, a sealant may be applied to the cover 10 to form a seal between the panel 14 and the frame 12. Suitably, a sealant is applied to either the first mating surface of the main body 12 a or the landing surface 12 c prior to attachment of the panel 14.

Each main body 12 a of the frame 12 may further include at least a first grooved section 22 running the length of the frame 12 configured to receive a decorative joint member 23 therethrough. As FIG. 4 illustrates, as two adjacent covers 10 are secured to a support surface 100 to form a joint there between, the first grooved sections 22 of adjacent frames 12 are aligned to receive a substantially straight decorative joint member 23 therethrough whereby the plane of the decorative joint member 23 is substantially parallel to the plane of the support surface 100. In one embodiment, the first grooved section 22 may comprise a curved surface effective to increase the load bearing capacity of the frame 12 as compared to a first grooved section 22 having a cornered surface. However, the first grooved section 22 may comprise a cornered surface or other surface configuration as desired.

The first grooved section 22 suitably runs a length up to about the length of the frame 12 to receive a decorative joint member 23 therethrough. Mostly used for aesthetic purposes, a plurality of decorative joint members 23 may be inserted at the joints into the first grooved section 22 of each frame 12 to conceal the joints. For example, when a plurality of rectangular covers 10 are used to form a continuous barrier on a support surface 100, a plurality of decorative joint members 23 may be inserted vertically and horizontally at the joints between the frames 12 of adjacent covers 10 to conceal the joints from view.

For ease of on-site installation, decorative joint members 23 may be made from sheet material similarly to the one or more panels 14. Thus, sheet material may be stored on-site and cut into strips to form decorative joint members 23 comprising lengths about equal to the height of the support surface 100. The decorative joint members 23 may then be inserted along the vertical joints through the grooved sections 22 while shorter decorative joint members 23 may be inserted along the horizontal joints between the vertically placed decorative joint members 23 to conceal the horizontal joints from view. In another embodiment, decorative joint members 23 comprising a length about equal to the width of the support surface 100 may be inserted along the horizontal joints through the grooved sections 22 while shorter decorative joint members 23 may be inserted along the vertical joints between the horizontally placed decorative joint members 23 to conceal the joints from view.

Although not necessarily limited to particular materials, a suitable decorative joint member 23 may be constructed from one or more materials similar to the materials forming the panel 14. Although the decorative joint members 23 do not necessarily have to be constructed from like materials as the one or more panels 14, a particular user may find it aesthetically pleasing to use similar materials for visual consistency. Thus, for example, the decorative joint member 23 and one or more panels 14 may be constructed from metal composite material. In another suitable embodiment, the decorative joint member 23 may be constructed from stainless steel while the corresponding panels 14 are constructed from metal composite material.

With further reference to FIG. 4, the lip 12 b of the frame 12 may be configured so that up to about the entire second surface 13 b of the lip 12 b abuts the support surface 100. Although the second surface 13 b of the lip 12 b and corresponding support surface 100 are shown as having substantially flat surfaces, it is herein contemplated that the second surface 13 b of the lip 12 b may be configured to abut a non-flat support surface 100. For example, the second surface 13 b of the lip 12 b may be curved to accommodate a corresponding curved support surface 100.

As FIG. 4 further illustrates, each frame 12 may comprise a second grooved section 24 at the interface between the main body 12 a and the lip 12 b. In one embodiment, the second grooved section 24 may comprise a curved surface. In another embodiment, the second grooved section 24 may comprise a cornered surface or other surface configuration as desired. In still another embodiment, the frame 12 may not include a second grooved section 24, but may instead include a solid core section thereby forming a thicker lip 12 b.

As stated above, the lip 12 b suitably extends perpendicularly from the main body 12 a a distance effective to receive a securing means 20 comprising a width up to about the width of the first surface 13 a. Although the lip 12 b is not limited to a particular size, the total width of adjacent lips 12 b, i.e., the width of a joint, is suitably less than the width of the cover 10. Thus, the distance between the second surfaces 15 b of adjacent panels 14 is less than the width of the first surface 15 a of the panel 14 (see FIG. 5A). Accordingly, the width of a decorative joint member 23 is also less than the width of the cover 10. In addition, the outer edge 18 a is suitably configured so that adjacent covers 10 can contact one another lengthwise, as discussed in more detail below.

The inner edge 18 b defining the inner perimeter of the frame 12 may also comprise various configurations as desired. For instance, the inner edge 18 b may be cornered, pointed, curved or rounded off. In a particularly advantageous embodiment, the inner edge 18 b defining the inner perimeter of the frame 12 is rounded off—as shown for example in FIGS. 4, 5B and 6. Suitably, a rounded off inner edge 18 b provides a cover 10 with superior load bearing capacity over other inner edge 18 b configurations when the cover 10 is secured to a support surface 100. For example, the stress concentration placed on a 90° squared off inner edge 18 b is greater than the stress concentration placed on a rounded inner edge 18 b. Thus, it is desirable that the entire perimeter of the inner edge 18 b be rounded off and configured to abut the support surface 100 during operation of the cover 10.

For the purposes of this application, a continuous barrier may be formed on a support surface 100 using one or more covers 10—depending on the total surface area of the support surface 100 in relation to the size of the cover(s) 10 to be secured thereto. In an embodiment incorporating a plurality of covers 10, the outer edges 18 a of a particular cover 10 may be self aligned near or against the outer edges 18 a of one or more adjacent covers 10 wherein the outer edges 18 a of adjacent covers 10 share common borders. Thus, the outer edge 18 a of a side of a second cover 11 may be self aligned flush against the outer edge 18 a of a side of a first cover 10 forming a joint between the covers 10—as illustrated in FIGS. 5A and 5B. In another embodiment, the outer edge 18 a of a side of a second cover 11 may be aligned near the outer edge 18 a of a side of a first cover 10 to form a joint between the covers 10.

Although the outer edges 18 a of the frames 12 are not necessarily limited to a particular shape, suitable outer edges 18 a of adjacent covers 10 may contact one another lengthwise. In another embodiment comprising adjacent covers 10 with outer edges 18 a aligned only near one another, the outer edges 18 a are suitably configured to at least contour one another lengthwise. As the figures illustrate, the lips 12 b suitably comprise straight outer edges 18 a, although non-straight outer edges 18 a are also herein contemplated.

To form a continuous barrier across a support surface 100 a plurality of covers 10 may be secured to the support surface 100 by aligning the outer edges 18 a of a second cover 11 with the outer edges of a first cover 10 that was randomly secured to the support surface 100. Thus, it is herein contemplated that a first cover 10 may be aligned in any orientation and secured to a support surface 100 at any location to form a continuous barrier across the support surface 100. For example, when employing a plurality of square shaped covers 10 to be secured to a rectangular support surface 100, the first cover 10 to be secured may be squared or otherwise aligned along the x-y axis of the support surface 100. Thereafter, each successive cover 10 may be aligned along the x-y axis by self-aligning the outer edge 18 a of each successive cover 10 adjacent the outer edge 18 a of a preceding cover 10. In another embodiment wherein the support surface 100 is not rectangular, covers 10 may still be leveled across the majority of the support surface 100 with dissimilar covers 10 used to form a barrier across the remaining support surface 100—as shown in FIG. 13.

Referring now to FIG. 6, an embodiment of a simplified cover 10 abutting a base surface 110 is shown. When secured to a substantially vertical support surface 100, i.e., a building exterior, each of the lowermost covers 10 may be secured to the support surface 100 to form a termination joint along the base. As illustrated, the outer edge 18 a of the lip 12 b suitably abuts the base surface lengthwise, as a securing means 20 is inserted through the lip 12 b to secure the frame 12 to the support surface 100. A sealant may be applied to the termination joint as desired.

Uppermost covers 10 may terminate along a support surface 100 by securing the frame 12 of the uppermost covers 10 along the top edge of the support surface 100. In the alternative, and depending on the configuration of the support surface 100, it may be desirable to form a continuous barrier over a top edge of the support surface 100 as shown in FIG. 7. As shown, one or more panels 14 of the uppermost covers 10 may be extended over an edge of the support surface 100 to form one or more end caps 26 covering the edge of the support surface 100. Each end cap 26 is suitably comprised of a panel 14 having a first end attached to a frame 12 forming a joint with an adjacent cover 10 as described in detail above. A second end of the panel 14 suitably extends over the top surface and attaches on an opposing rear surface via securing means 20 forming end caps 26. A sealant may also be applied to the end caps 26 along the space between adjacent panels 14 as desired. In one embodiment, the end cap 26 may include two bends, as shown in FIG. 7. Alternatively, the end cap 26 may be rounded off, or rise to a pointed edge.

Not only is the present cover 10 operationally configured to secure to a planar support surface 100, the cover 10 may also be secured to a non-planar support surface 100. For example, a cover 10 may be secured along an outside corner of a support surface 100—as encountered when forming a continuous barrier across two or more sides of a building exterior. FIG. 8 illustrates a cross sectional view of an embodiment of a rectangular cover 10 secured to an outside corner of a support surface 100. As shown, the cover 10 can be bent to an angle substantially similar to the bend angle of the outside corner. Although not necessarily limited to a particular bend radius, a suitable panel 14 may comprise a bending radius up to about fifteen times the thickness of the panel. Thus, the cover 10 described herein can be bent from about 30° to about 150°. As exemplified in FIG. 8, the outside corner and corresponding cover 10 each comprise a bend angle of approximately 90°.

As FIG. 8 further illustrates, a cover 10 is suitably secured to an outside corner of a support surface 100 in similar fashion as covers 10 secured to relatively flat support surfaces 100. In one embodiment, a cover 10 may be centered on the outside corner of a support surface 100 whereby the panel first surface 15 a comprises equidistant perpendicular faces, and the opposite ends of the frame 12 are secured to the support surface 100 substantially the same distance from the outside corner—as shown in FIG. 8. In another embodiment, the panel first surface 15 a may include perpendicular faces of different lengths. In another embodiment, the corner of the panel 14 may be rounded off. In still another embodiment, the panel 14 may include two bends providing a panel first surface 15 a having three faces—effectively cutting off the corner.

As FIG. 9 illustrates, the present cover 10 may also be secured to an inside corner of a support surface 100—as encountered when forming a continuous barrier at a soffit or an inside corner of a wall. Suitably, adjacent covers 10 are secured to an inside corner at interfacing support surfaces 100, wherein one end of a frame 12 of a first cover (listed as 10A) is secured to a first support surface 100-A as described above and secured to a second support surface 100-B at a second end effectively covering the inside corner of the support surface—as shown in FIG. 9. In this embodiment, the panel 14 of cover 10A does not include a return portion at the second end, but instead attaches directly to the first surface of the main body 12 a forming a joint between adjacent covers 10A and 10B on support surface 100-B. In an alternative embodiment, a joint may be formed between adjacent covers 10A and 10B on support surface 100-A.

In certain instances, a support surface 100 may include one or more second protruding surfaces 200 at a particular point on an otherwise substantially flat support surface 100. Typical protruding surfaces include, but are not necessarily limited to door frames or jambs, window frames or jambs, entry openings, and presentation ways. To effectively form a continuous barrier across the support surface 100, it may be necessary to secure a plurality of covers 10 along the outer perimeter of the protruding surface 200.

FIG. 10 illustrates a simplified joint formed between a cover 10 and a protruding surface 200. As shown, a cover 10 can be mounted close to flush against a corresponding protruding surface 200. Unlike the embodiment for covering an inside corner as described above, here a second panel 14 a can be inserted at the joint to cover the corner junction between the support surface 100 and protruding surface 200. As shown, the second surface 13 b of a frame 12 can be set to interface the second panel 14 a whereby a securing means 20 can be inserted through both the frame 12 and the second panel 14 a to secure the cover 10 and seal part of the joint. The non-secured portion of the second panel 14 a can then be sealed to the protruding surface 200 via a sealant 40.

An advantage of the cover 10 described herein includes that any particular number of covers 10 may be used to form a continuous barrier on a particular support surface 100 by first determining (1) the total surface area of the support surface 100 and (2) the size and shape of cover 10 to be used. Thus, in one embodiment, a total of one hundred square foot covers 10 can be aligned in ten rows of ten covers 10 across a 10 foot—10 foot support surface 100 to form a continuous barrier on the support surface 100. In another embodiment where a smaller cover 10 is desired, a total of two hundred six inch square covers 10 can be aligned in twenty rows of twenty covers 10 across a 10 foot×10 foot support surface 100 to form a continuous barrier on the support surface 100. In another embodiment, covers 10 having right triangles can be used to form a continuous barrier on the support surface 100—as seen in FIG. 11.

As illustrated in FIG. 12, a combination of non-uniform shaped covers 10 can be used to form a continuous barrier on the support surface 100. In this embodiment, no two cover 10 center points are necessarily aligned along similar horizontal or vertical rows/columns. Yet, a continuous barrier may be formed on the support surface 100 nonetheless based on the independent securability and sealability of the individual covers 10. In this embodiment, persons may pre-mark or outline the support surface 100 with various shapes of varying sizes on the support surface 100 using chalk and the like. Corresponding covers 10 can then be assembled and placed on the support surface 100 to cover each of the distinct pre-marked areas. Thus, the cover 10 described herein is not limited to any one particular aesthetic presentation on a support surface 100.

In similar fashion, one or more covers 10 may be secured to a support surface 100 along a non-level base surface 110—as FIG. 13 illustrates. The independent securing of individual covers 10 to a support surface 100 is therefore an advantageous feature of the present application because it allows a user to construct a cover 10 of any size and shape on-site necessary to cover a non-uniform or otherwise unexpected exposed support surface 100 configuration.

As mentioned above, a sealing member may be disposed between the cover 10 and the support surface 100 as desired. Suitably, a gasket material may be employed that is operationally configured to cover at least the second surface 13 b when the cover 10 is secured to a support surface 100, thereby forming a vapor barrier along the perimeter of the cover 10 resistant to penetration by water and other fluids. In one embodiment, a gasket is applied to a support surface 100 prior to securing the cover 10 to the support surface 100, wherein the gasket may be placed on the support surface 100 in an orientation corresponding to the desired orientation of the cover 10 on the support surface 100. Alternatively, a gasket may be applied to the second surface 13 b of a frame 12 prior to securing the cover 10 to the support surface 100. In one suitable embodiment, a gasket material may be applied to either the support surface 100 or second surface 13 b via a “peel and stick” technique. It is herein contemplated that a vapor barrier may also be formed by applying one or more sealants to either a support surface 100 or second surface 13 b in addition to, or in place of a gasket material.

A suitable gasket material includes, but is not necessarily limited to a weather resistant material such as rubber, a synthetic rubber such as neoprene, elastomer, structural silicone. A suitable elastomer includes but is not necessarily limited to a thermoplastic elastomer such as Santoprene®. A suitable sealant includes, but is not necessarily limited to caulk made from silicone, polyurethane, polysulfide, sylil-terminated-polyether or polyurethane, and acrylic sealant. A sealant may also be applied to each of the joints described above to further seal the support surface from the ambient environment. A suitable joint sealant includes but is not necessarily limited to the caulk materials listed above.

It is herein contemplated that the cover 10 may be secured to various exterior and interior support surfaces 100 including, but not necessarily limited to plywood, sheetrock, tin, brick, concrete, metal and plasterboard. Thus, one or more covers 10 may be mounted on a support surface 100 as cladding, used to seal asbestos within a support surface 100, used as decorative wall coverings, used as column covers, and as covers for monoliths.

The cover 10 may be assembled on-site as described above and then secured to a support surface 100 by one or more individuals. In a simplified illustration, a user may (1) place an individual cover 10 against a support surface 100 at a target location, (2) align a conventional screw at a point along the scored region 30 of the cover 10, (3) use a common drill to insert the screw into the support surface 100, (4) repeat steps 2 and 3 until a desired number of screws are securing the cover 10 to the support surface 100. A second cover 10 can then be secured to the support surface 100 by repeating steps 1 through 4. The second cover 10 may be set adjacent the first cover 10, or in the alternative, set apart from the first cover 10 on the support surface 100.

The invention will be better understood with reference to the following non-limiting example, which is illustrative only and not intended to limit the present invention to a particular embodiment.

EXAMPLE 1

In one non-limiting example, a one foot square architectural cover 10 is assembled having the following properties:

Frame: Four one foot extruded aluminum sections edge mitered to 45° Panel: Aluminum Composite Material approximately thirteen inches square Height of Cover: about 35.0 mm (about 1.38 inches).

As will be understood by those of ordinary skill in the art, and others, many modifications may be made without departing from the spirit and scope of the invention. The embodiments described herein are meant to be illustrative only and should not be taken as limiting the invention, which is defined in the following claims. 

1. An architectural cover for securing to a support surface comprising: a frame defining a perimeter; a panel overlying a portion of the frame to form an exterior side of the cover and an interior side of the cover; the frame further comprising (a) a main body configured to attach to the panel via a fastening means, and (b) a lip defined by a first surface configured to receive a securing means, and a second surface configured to abut the support surface; the lip further comprising an outer edge defining a perimeter of the cover and an inner edge defining an inner perimeter of the frame, the perimeter of the inner edge configured to abut the support surface when the architectural cover is secured to the support surface.
 2. The architectural cover of claim 1, wherein the frame is assembled from three or more longitudinal frame members of unequal lengths.
 3. The architectural cover of claim 1, wherein the frame further includes a first grooved section configured to receive a decorative joint member therethrough.
 4. The architectural cover of claim 1, wherein the frame further includes a bend up to about 90° forming a landing surface.
 5. The architectural cover of claim 1, wherein the lip further comprises a first surface for receiving a securing means.
 6. The architectural cover of claim 5, wherein the lip further comprises a second surface.
 7. The architectural cover of claim 4, wherein the first surface further comprises a scored region.
 8. The architectural cover of claim 1, wherein the inner edge is rounded off.
 9. The architectural cover of claim 1, wherein the panel forms an end cap over an edge of the support surface.
 10. A system for forming a continuous barrier on a support surface comprising: a plurality of architectural covers, the architectural covers being secured adjacent one another on the support surface forming joints there between; wherein each architectural cover forms an independent relationship with the support surface when secured to the support surface.
 11. The system of claim 10, wherein adjacent covers have centers that are different distances from the top and bottom edges of the support surface.
 12. The system of claim 10, further including decorative joint members inserted at the joints between the architectural covers.
 13. The system of claim 10, wherein each architectural cover comprises a different size, different shape and different number of sides.
 14. The system of claim 13, wherein each architectural cover can be secured to the support surface using like securing means without regard to the size and shape of the architectural covers.
 15. A system for forming a continuous barrier on a support surface comprising: two or more architectural covers, each cover having a frame and a panel, wherein the frame comprises three or more sides defining a perimeter, the frame being securable to the support surface; the panel overlying the frame to form an exterior side of the cover and an interior side of the cover; one or more decorative joint members; wherein the two or more covers are secured adjacent one another on the support surface forming joints there between; wherein the two or more covers form an independent relationship with the support surface when secured to the support surface; and wherein the decorative joint members are inserted at the joints between the frames of adjacent covers to conceal the joints from view.
 16. The system of claim 15, further comprising sealing members disposed between the covers and the support surface when the covers are secured to the support surface.
 17. The system of claim 15, wherein each architectural cover comprises a different size, different shape and different number of sides.
 18. The system of claim 15, wherein the architectural covers may be secured to the support surface in a non-sequential manner.
 19. A method for forming a continuous barrier on a support surface using a plurality of architectural covers, the method comprising: providing a plurality of architectural covers, each architectural cover comprising a frame defining a perimeter, and a panel overlying the frame to form an exterior side of the cover and an interior side of the cover; the frame further including a main body configured to attach to the panel via a fastening means, and a lip defined by a first surface configured to receive a securing means, and a second surface configured to abut the support surface; the lip further comprising an outer edge defining a perimeter of the cover and an inner edge defining an inner perimeter of the frame, the perimeter of the inner edge configured to abut the support surface when the architectural cover is secured to the support surface; randomly securing successive architectural covers directly to the support surface wherein the outer edges of each architectural cover share common borders with the outer edges of adjacent architectural covers.
 20. The method of claim 19, wherein the support surface is pre-marked to form areas having various shapes of varying sizes each configured for placement of a corresponding cover. 